Safety tap handle

ABSTRACT

An apparatus is disclosed for a tap handle for beverage dispensing comprising a ceramic, porcelain, or stoneware handle filled with a foam, preferably polyurethane foam which renders the tap handle more resilient and resistant to sharding. Ideally, polymeric diphenylmethane diisocyanate foam is injected into a tap handle shell in liquid form, which solidifies and is capped with a glue, an internally threaded cap and a protective plastic cap.

The present application is a continuation of U.S. patent applicationSer. No. 10/750,074, filed Dec. 31, 2003. The present application isbased on and claims priority from this application, the disclosure ofwhich is hereby expressly incorporated herein by reference in itsentirety.

BACKGROUND OF INVENTION

The invention relates to beverage dispensing accessories. Moreparticularly, the invention relates to an improved, strengthenedceramic, hardened foam filled tap handle having shatter resistant andresilient safety characteristics.

Restaurants, bars, pubs and nightclubs and other establishments employpressurized beverage delivery systems where the flow of the beverage,typically beer, is regulated by a tap. The tap is usually mounted on thebar, and is operated by a tap handle which is rotated forward to open avalve in the tap and pour the beverage into a glass. Various types oftaps and valves are used. It has become standard in the industry todisplay the name and often a logo of the brewer on the tap handleassociated with the beverage dispensed from that particular tap.Historically, tap handles have been manufactured from wood, resin,plastic and ceramic. Recently ceramic handles have become popular as ahigh quality accessory which showcases the logo and name of the brewer.Due to strict regulations governing the display of brewers' tradenames,trademarks and logos in liquor serving establishments, tap handles havebecome an important advertising medium.

Ceramic tap handles, although popular, are dangerous as they arebrittle, and if struck, tend to shatter into sharp edged shards. Thelack of strength and durability renders current ceramic handles lesscost effective and a liability, as injuries to operators or customersmay occur when handles break.

BRIEF SUMMARY OF THE INVENTION

It is an object of the present invention to implement a tap handle thatovercomes some of the disadvantages of the prior art.

An object of the present invention is to provide a tap handle with aceramic shell filled with foam, thereby providing a stronger, shardresistant tap handle. The foam filling may be capped by a glue plug.

Another object of the present invention is to implement a liquidinjected foam which hardens to provide structural strength to the taphandle shell and includes adhesive properties, and may be used withceramic, wood, plastic or resin shells. Advantageously, the foam is aPolyurethane foam (PMDI).

Still another object of the present invention is to provide a method ofmanufacturing tap handles by firing a ceramic shell, injecting liquidfoam into the shell, then injecting glue into the shell to cement aninternally threaded ferrule in place.

Further advantages of the invention will become apparent whenconsidering the drawings in conjunction with the detailed description.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a side elevation view of a preferred embodiment of the taphandle that is the subject of the present invention, mounted on a tap.

FIG. 2 is a centerline cross sectional view of a safety tap handleaccording to the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 depicts an embodiment of the apparatus for an improved safety taphandle 10 used for selectively opening and closing a tap valve on apressurized beverage system in accordance with the present invention. Ingeneral, the tap handle 10 consists of an elongated hollow shell 12 withan open end 11. According to the invention, a hardened foam 14 fills theinterior of the shell 12, and the open end 11 is sealed with glue 16 anda threaded ferrule 18. Finally, a plastic cap 20 may be placed on top ofthe ferrule 18 in the preferred embodiment.

The tap handle 10 is adapted to screw onto a tap 24. Tap handles 10 aredistinctive of the brand of beverage being dispensed on the particulartap 24. They, therefore, vary in size, shape, and color and often bearthe tradename, trademark, and logo of a particular beverage suppliersuch as a brewery. Tap handles 10 are typically elongated structuresusually between 30-60 mm (1.2″-2.4″) in diameter and 200-300 mm(7.9″-12″) in length sized to fit the hand. It is standard in thebeverage dispensing industry for tap handles 10 to include an internallythreaded connector or ferrule 18 which mates with a threaded connector,or handle stud 26 projecting upwards from the tap 24, usually attachedto a bar. It is standard in the industry that the handle stud 26 is9.525 mm (⅜″) in diameter. The distinctive tap handles 10 are theneasily interchangeable between taps 24 when the pressurized beveragedelivered to the tap 24 is changed. In operation, the tap handle 10 istypically pulled towards the operator, thereby, opening a valve (notshown) in the tap 24, and dispensing the beverage. Many variations oftaps 24 are employed, although the rotational valve version is used byway of example here.

The present invention is an improved tap handle 10, which isstrengthened and shard resistant due to a foam 14 injected filling. Aceramic tap handle shell 12 is manufactured from a mold (not shown)which can be of a design distinctive to a particular beverage supplier,typically a brewery. The shell 12 commences as greenware, to which glazeis applied, and distinctive decals are added. The shell 12 is then kilnfired to produce the hardened shell 12, with the distinctive decals 22integral to the shell 12. The shell 12 is preferably ceramic stonewarein the preferred embodiment, although it may be porcelain.

Ceramic is desirable as it is an aesthetically pleasing, high qualitymaterial recognized in the industry as a premium accessory in beverageequipment. The brittle nature of ceramic results in breakage of taphandles 10 in the busy beverage service environment and can result ininjury when the tap handles 10 shard, or shatter into pieces, leavingsharp exposed edges. A foam 14 filling is, therefore, injected into theceramic shell 12 to overcome these disadvantages.

During manufacturing, the hardened shell 12 is inverted so the open end11 is at the top. A foam, preferably a polyurethane foam in liquid form,is injected into the shell 12. The foam hardens over a period of 1-2hours using the preferred material. In variations of the preferredembodiment, other foam products and fillings may be used which fill theinterior, such as polystyrene. In the preferred embodiment, RT-5011-Apolymeric diphenylmethane diisocyanate (PMDI) polyurethane foam is usedto maximize the resulting resilience and anti-sharding qualities of thetap handle 10. The foam 14 ideally contains 58-74% w/w polyether polyol,22-27% w/w 1,1-dichloro-1-fluoroethane, and 8-12% w/w siliconesurfactant in the preferred embodiment, although variations of theconstituent ingredients and the percentage composition may be used.Ideally, 70-90% of the shell 12 is filled with foam 14, which istypically to within 20-50 mm of the open end 11 of the shell 12. Whenthe foam 14 has hardened, a liquid glue 16 is injected into the open end11 of the shell 12, filling the remaining 20-50 mm deep space, to withinapproximately 2-6 mm from the open end of the shell 12.

In the preferred embodiment, a thermomelt gun is employed with, forinstance, thermomelt glue is appropriate for bonding to steel andceramic. Alternatively, an epoxy (e.g. JET™ cure epoxy) may be used.Epoxy, while resulting in a structurally stronger bond between the shell12, foam 14, and ferrule 18, requires considerable time (usually 24hours) to cure. (Use of epoxy also requires clamping of the shell 12during the curing period.) Epoxy may be employed with larger tap handles10 where the torsion applied to the tap handle 10 during operationrequires increased strength. The thermomelt glue is advantageous wherecareful placement of the ferrule 18 is important for aligning the shell12 with the tap 24, for instance. The thermomelt glue is alsoadvantageous where speed of production is important, as it hardens inless than 10 minutes, allowing for rapid assembly.

An internally threaded ferrule 18 is then inserted into the bed of glue16. An annular plastic washer or cap 20 is then glued over the ferrule18 to cap the lower end of the tap handle 10 so that glue 16 does notleak out of the open end 11 of the tap handle 10. The cap 20 isoptional, and serves to retain the glue plug in place.

In operation, the tap handle 10 is screwed onto the handle stud 26projecting upwards from the tap 24. The tap handle 10 is pulled forwardto pour the beverage (not shown).

The function of the foam 14 is three-fold. Primarily, the foam 14adheres to the porous interior surface of the shell 12 so that if thetap handle 10 is impacted heavily and breaks, the foam 14 binds thepieces of the shattered shell 12 together, such that the sharp edges ofthe ceramic are not exposed. Injuries are, thereby, avoided. Secondly,the lightweight foam 14 substantially increases the resilience andstrength of the tap handle 10 such that it can withstand substantiallygreater impacts than prior art handles without breaking. The foam 14 issuperior to other materials as it is solid, but compacts under impact,thereby, reducing the chance of fracture of the shell 12 as the foam 14decelerates impacting forces over a greater period of time than a morebrittle material. This increases the durability of tap handles 10 and ismore cost effective. Finally, the inherent adhesive qualities of thefoam 14 act to cement the tap handle 10 into a single unit, includingthe shell 12, glue plug 16, ferrule 18, and cap 20. The presentinvention, thereby, renders high quality ceramic tap handles 10 as ormore durable and safe than alternative, less aesthetically pleasinghandles made from wood, plastic or resin.

FIG. 2 is a centerline cross sectional view of a tap handle 10 accordingto the invention. The shell 12 is optimally 2-3 mm thick but may be ofany thickness up to 12 mm (0.472″), at which point firing and annealingbecomes impractical. Ideally, the foam 14 fills approximately 90% of theinterior of the shell 12. The foam 14 is sealed by a glue plug 16, whichalso adheres to the interior surface of the shell 12 and a metal ferrule18.

The ferrule 18 is preferably steel, annular in shape, and is internallythreaded to receive the externally threaded handle stud 26 (not shown),which extends from the tap (not shown). Variant ferrules 18 may beemployed. In one variation, the ferrule 18 is secured to the shell 12 bya bolt (not shown), which extends longitudinally along the centerline ofthe shell 12 and extends out the top of the shell 12 through a smallhole. A nut or finial (not shown) is then secured to the end of the boltand tightened against the top of the shell 12. The foam 14 is injectedabout the longitudinal bolt (not shown). The sizing is standard in theindustry to facilitate interchangeability of tap handles. In thisvariation, a cap 20 is not employed. The ferrule 18 is typically aninverted frustro-conical shape, with sides flush to the exterior surfaceof the shell 12 and a diameter that diminishes towards to tap 24. In anadditional variation, the ferrule 18 includes an anchor bolt 28extending vertically from its top surface. The anchor bolt 28 isenveloped by the glue plug 16 and once hardened, anchors the shell 12and foam 14 to the ferrule 18. The anchor bolt 28 may also extend intothe foam 14.

It should be understood that the above description is intended forillustrative purposes only, and is not intended to limit the scope ofthe present invention in any way. Those skilled in the art willappreciate that various modifications can be made to the embodimentsdiscussed above without departing from the spirit of the presentinvention.

1. An improved tap handle for use with a beverage dispensing apparatus comprising: (a) a hollow shell having at least one open end; and (b) a hardened foam disposed within said shell; (c) said foam adheres to and reinforces said shell.
 2. A tap handle according to claim 1, wherein said shell is comprised, at least in part, of ceramic material.
 3. A tap handle according to claim 2, wherein said ceramic material is stoneware.
 4. A tap handle according to claim 2, wherein said ceramic material is porcelain.
 5. A tap handle according to claim 1, wherein said shell is comprised, at least in part, of plastic.
 6. A tap handle according to claim 1, wherein said shell is comprised, at least in part, of resin.
 7. A tap handle according to claim 1, wherein said shell is comprised, at least in part, of wood.
 8. A tap handle according to claim 1 additionally comprising a layer of glue or epoxy disposed inside said shell proximate to an open end between said foam and said open end.
 9. A tap handle according to claim 8 additionally comprising an annular, ferrule having internal threads and a top and bottom and being disposed in said interior of said shell, said bottom abutting said glue or epoxy.
 10. (canceled)
 11. A tap handle according to claim 1 wherein said foam is polyurethane foam.
 12. A tap handle according to claim 11 wherein said foam is polymeric diphenylmethane diisocyanate foam.
 13. A resilient, shatter resistant ceramic ware comprising a hollow shell having at least one opening with a hardened polyurethane foam filling such that said foam adheres to and reinforces said shell.
 14. The ceramic ware of claim 13, wherein said foam is a polymeric diphenylmethane diisocyanate foam.
 15. A method of manufacturing a safety tap handle for use in beverage dispensing comprising the steps of: (a) firing a ceramic shell having at least one open end; (b) injecting liquid foam into said shell such that it is 80-90% filled; and (c) curing said foam until it is hardened and adheres to said shell; thereby, rendering said tap handle resilient and resistant to breaking and sharding.
 16. The method of claim 15 further comprising the step of monitoring and adjusting the temperature of the cooling foam following step (b).
 17. The method of claim 15 further comprising the step (d) of injecting a plug of glue or epoxy proximal to an open end and abutting said hardened foam.
 18. The method of claim 17 further comprising the step (e) of inserting a ferrule at an open end in said glue or epoxy plug.
 19. A tap handle according to claim 1, wherein said shell has a porous interior surface and said foam adheres to said porous interior surface.
 20. A tap handle according to claim 1, wherein said shell has an interior surface and said foam adheres to said interior surface.
 21. The ceramic ware of claim 13, wherein said shell has a porous interior surface and said foam adheres to said porous interior surface. 